HVAC Module Assembly Replacement LHD
Tools Required
Electronic Leak Detector.
Removal Procedure
Caution: Refer to Safety Glasses Caution in the Preface section.
- Recover the refrigerant. Refer to
Refrigerant Recovery and Recharging
.
- Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- Drain the cooling system. Refer to
Cooling System Draining and Filling
.
- Remove the instrument panel (I/P) pad. Refer to
Instrument Panel Upper Trim Pad Replacement
- Remove the instrument panel carrier. Refer to
Instrument Panel Carrier Replacement
- Remove the instrument panel centre support bracket. Refer to
Instrument Panel Retainer Replacement
.
- Disconnect the HVAC module assembly electrical connector.
- Mark and remove the heater hoses (1) from
the heater core pipes.
- Remove the suction hose from the thermal expansion valve. Refer to
Suction Hose Replacement
.
- Remove the three HVAC mounting screws (1)
in the engine bay.
- Remove the HVAC module assembly mounting
screws (1) in the cabin.
- Remove the HVAC module assembly from the vehicle.
Installation Procedure
Important: Ensure the drain pipe docks with the drain
assembly.
- Install the HVAC module assembly to the vehicle.
Notice: Refer to Fastener Notice in the Preface section.
- Install the screws from inside the vehicle which secure the HVAC module assembly.
Tighten
Tighten the nuts to 9N·m (80 lb in).
- Install the screws from the engine compartment
which secure the HVAC module assembly.
Tighten
Tighten the nuts to 7N·m (62 lb in).
- Install the suction hose to the thermal expansion valve. Refer to
Suction Hose Replacement
.
- Install the heater hoses to the heater core
pipes.
- Install the instrument panel support bracket. Refer to
Instrument Panel Retainer Replacement
- Install the instrument panel carrier. Refer to
Instrument Panel Carrier Replacement
- Install the instrument panel (I/P) pad. Refer to
Instrument Panel Upper Trim Pad Replacement
- Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.
- Evacuate and recharge the A/C system. Refer to
Refrigerant Recovery and Recharging
.
- Leak test the fittings of the component using electronic leak detector.
HVAC Module Assembly Replacement RHD
Tools Required
Removal Procedure
Caution: Refer to Safety Glasses Caution in the Preface section.
- Recover the refrigerant. Refer to
Refrigerant Recovery and Recharging
.
- Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- Remove the engine cover. Refer to
Engine Cover Replacement
in Engine Mechanical - 3.6L or
Engine Cover Replacement
Engine
Mechanical - 6.0L
- Drain the cooling system. Refer to
Cooling System Draining and Filling
.
Important: Mark position of heater hoses (3)
and heater hose retaining clamps (1) before removal to make sure of correct
alignment during assembly.
- Using
J 38185
compress the
heater hose retaining clamps (1) and slide 50 mm (2 in) along
the heater hose (3).
- Remove the heater hoses (3) from the heater core pipes (2).
- Remove the exhaust manifold heat shield to air box retaining
clips (2).
- Remove the exhaust manifold heat shield (1).
- Remove the insulation panel to air box retaining clips (2).
- Remove the insulation panel (1) from the engine compartment.
- Remove the remote battery positive post cover (1).
- Remove the remote battery positive post to wiring harness retaining bolt (1).
- Remove the starter motor power cable (2) and position aside.
- Remove the suction pipe upper to suction pipe lower retaining nut (1).
- Remove the suction pipe/liquid pipe retaining clip to
left front chassis rail retaining bolt (3).
- Detach the liquid pipe (1) from the suction pipe/liquid pipe retaining
clip (2).
- Disconnect the suction pipe upper (1) from the
suction pipe lower (2).
Important: The sealing washer (3) is a single
use item and must be discarded after use.
- Remove the sealing washer (3). Refer to
Sealing Washer Replacement
.
Discard the sealing washer
Important: Cover any opening of the A/C system with
a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.
- Cap or plug the suction pipe upper (1) and the suction pipe lower (2).
- Remove the suction pipe/liquid pipe pad to thermal expansion
(TX) valve retaining nut (1).
- Disconnect the suction pipe/liquid pipe pad (3)
from the TX valve (1).
Important: The sealing washers (2) are a single
use item and must be discarded after use.
- Remove the sealing washers (2). Refer to
Sealing Washer Replacement
.
Discard the sealing washers
Important: Cover any opening of the A/C system with
a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.
- Cap or plug the suction pipe (4), liquid pipe (5) and the TX valve (1).
- Remove the HVAC module assembly to bulkhead retaining
bolts (1).
- Remove the I/P centre support bracket. Refer to
Instrument Panel Retainer Replacement
.
- Remove the I/P upper trim pad. Refer to
Instrument Panel Upper Trim Pad Replacement
- Remove the HVAC module assembly to vehicle body retaining
screws (1).
- Remove the I/P carrier. Refer to
Instrument Panel Carrier Replacement
Important: To remove the HVAC module assembly from the
vehicle move the HVAC module assembly towards the back of the car off the drain assembly
and downwards to clear locating pins from datum bracket.
- Remove the HVAC module assembly (3) from the vehicle body (2).
Installation Procedure
Important: Make sure the HVAC module assembly (3)
fits into the drain assembly
- Install the HVAC module assembly to the vehicle (2).
- Install the instrument panel (I/P) carrier. Refer to
Instrument Panel Carrier Replacement
Notice: Refer to Fastener Notice in the Preface section.
- Install the HVAC module assembly to I/P carrier retaining screws (1).
Tighten
Tighten the screws to 9 N·m.80 lb in.
- Install the I/P upper trim pad. Refer to
Instrument Panel Upper Trim Pad Replacement
- Install the I/P retainer bracket. Refer to
Instrument Panel Retainer Replacement
.
- Install the HVAC module assembly to bulkhead retaining
bolts (1).
Tighten
Tighten the nuts to 7 N·m.62 lb in.
- Remove the plugs or caps from the suction pipe (4),
liquid pipe (5) and the thermal expansion (TX) valve (1).
Important: DO NOT coat the NEW sealing washers (2)
with oil, they must be fitted dry. The use of mineral oil will render the sealing
washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant
to leak out.
- Install NEW sealing washers (2). Refer to
Sealing Washer Replacement
.
- Connect the suction pipe/liquid pipe pad (3) to the TX Valve (1).
Notice: Refer to Fastener Notice in the Preface section.
- Install the suction pipe/liquid pipe pad to TX valve retaining nut (1).
Tighten
Tighten the nut to 22 N·m(16 lb ft).
- Remove the plugs or caps from the suction pipe upper (1) and the suction
pipe lower (2).
Important: DO NOT coat the NEW sealing washer (3)
with oil, they must be fitted dry. The use of mineral oil will render the sealing
washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant
to leak out.
- Install a NEW sealing washer (3). Refer to
Sealing Washer Replacement
.
- Install the suction pipe upper (1) to the suction pipe lower (2).
- Attach the liquid pipe (1) from the suction pipe/liquid
pipe retaining clip (2).
- Install the suction pipe/liquid pipe retaining clip to left front chassis
rail retaining bolt (3).
- Install the suction pipe upper to suction pipe lower retaining nut (1).
Tighten
Tighten the nut to 22 N·m( 16 lb ft).
- Install the starter motor positive cable (2) to the remote battery positive
post.
- Install the remote battery positive post to wiring harness retaining bolt (1).
Tighten
Tighten the bolt to 15 N·m (11 lb ft).
Important: Make sure the clips on the remote battery
positive post cover (1) are engaged to avoid an induced rattle condition.
- Install the remote battery positive post cover (1) to the remote battery
positive post.
- Install the insulation panel (1) to the left rear
side engine compartment.
- Install the insulation panel to air box retaining clips (2).
- Install the exhaust manifold heat shield (1).
- Install the exhaust manifold heat shield to air box retaining clips (2).
- Connect the heater hoses (3) to the heater core
pipes (2).
- Using
J 38185
, slide
the heater hose retaining clamps (1) back into the original position on the
heater hoses (3).
- Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.
- Evacuate and recharge the A/C system. Refer to
Refrigerant Recovery and Recharging
.
- Leak test the fittings of the component using
J 39400
.
- Install the engine cover. Refer to
Engine Cover Replacement
in Engine Mechanical - 3.6L or
Engine Cover Replacement
Engine
Mechanical - 6.0L